Foundry mixing machine

ABSTRACT

A foundry mixing machine is disclosed for mixing a mold material component with a binder component comprising a rotating rotor means to mix the components by action of centrifugal force. The invention is suitable for use with multi-component binders being able to mix two of the three components by a first mixing means and to mix the remaining component with the mixed components by a second mixing means. The foregoing abstract is merely a resume of one general application, is not a complete discussion of all principles of operation or applications, and is not to be construed as a limitation of the scope of the claimed subject matter.

United States Patent Rebish FOUNDRY MIXING MACHINE PrimaryExaminerRobert W. Jenkins AttorneyWoodling, Krost, Granger and Rust [57] ABSTRACT A foundry mixing machine is disclosed for mixing a moldmaterial component with a binder component comprising a rotating rotormeans to mix the components by action of centrifugal force. Theinvention is suitable for use with multi-component binders being able tomix two of the three components by a first mixing means and to mix theremaining component with the mixed components by a second mixing means.The foregoing abstract is merely a resume of one general application, isnot a complete discussion of all principles of operation orapplications, and is not to be construed as a limitation of the scope ofthe claimed subject matter.

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PATENTEDNUY 20 I975 IN VE TOR ED WA RD J. REB/SH W m 1 2 ATiZDi'NEYSFOUNDRY MIXING MACHINE BACKGROUND OF THE INVENTION This inventionrelates to mixing machines and more particularly to foundry mixingmachines for mixing a mold material component and a binder component.

The prior art foundry mixing machines can be generally divided into twotypes. The first type of mixing machine included machines having aninternal impeller or an internal mixing blade to mix a mold materialcomponent with a binder component. This type of mixer workedsatisfactorily but would experience clogging after a period of use. Asubstantial amount of mold material component was also wasted at thebeginning and end of each mixing cycle. In addition, the cleaning of themachine after completion of a mixing cycle was a difficult task. Themixed mold material and binder component within the machine wasconstantly deteriorating causing non-uniformity in material output dueto delays and the like. A further disadvantage of this type of machinewas the wear suffered by the impellers and other internal moving partsdue to the abrasive quality of mold material.

A second type of prior art mixing machine included those generallyclassified as a centrifugal force r'nixing machine. In these machines,the material component would fall in proximity to a rotating disc whichdispersed the coating component therefrom. However, this type of mixingmachine did not offer a complete mixing due to the fact that largedroplets of the coating component would be dispersed by the rotatingdisc causing portions of the material component to be saturated andleaving other portions of the material component unmixed. In addition,these machines were unable to function with the large variety of moldmaterial components and binder components required by many foundries.Therefore, these machines never found an application in the foundryindustry but were restricted to merely coating processes.

The difficulties of the prior art foundry mixing machines became moreacute with the introduction of a multicomponent binder into the foundryindustry. The first type of mixing machine had to be modified to includethree impellers. Two of the impellers were used to mix each of thebinder components with a portion of the mold material component and thethird impeller was used to mix the two binder components. This increasedthe cost and complexity of these machines and the problem of clogging inthe third impeller was still present. For some of the rapidly curingmulticomponent binders, the impeller type mixing machine was completelyimpractical since the machine could not mix the binder componentsrapidly enough to avoid the binder curing within the machine.

The use of the multicomponent binder was also inapplicable to the priorart centrifugal force mixing machines. Generally, these centrifugalmixing machines dispersed the coating components in large droplets anddid not afford proper mixing to the components. The mixing process wasfurther complicated by the fact that material component was not freelyfalling during the entire mixing process. This caused the materialcomponent to be closely packed which resisted penetration by the coatingcomponent. Thus, the centrifugal force mixing machines were stillinapplicable to a foundry mixing process.

Therefore, an object of this invention is to produce a foundry machinefor mixing a mold material component and a binder component which usescentrifugal force as a method of mixing and can disperse the bindercomponent into a fine dispersion to insure proper mixing.

Another object of this invention is to produce a foundry machine formixing a mold material component and a binder component which is easy touse, requires only infrequent cleaning and can be easily cleaned.

Another object of this invention is to produce a foundry machine formixing a mold material component and a binder component which is capableof having a two-stage mixing process.

Another object of this invention is to produce a foundry machine formixing a mold material component and a binder component which isinexpensive.

Another object of this invention is to produce a foundry machine formixing a mold material component and a binder component which has littleor no waste at the beginning and end of each mixing cycle.

Another object of this invention is to produce a foundry machine formixing a mold material component and a binder component which is capableof accommodating a variety of mold material components and bindercomponents.

SUMMARY OF THE INVENTION The invention may be incorporated in a foundrymachine for mixing a mold material component and a binder having a firstand a second component, comprising in combination, discharge means forthe mold material component, first mixer means to mix two of thecomponents, second mixer means to mix a third component with theaforementioned two components, rotatable rotor means, said second mixermeans including director means directing the mold material emanatingfrom said discharge means to substantially envelop said rotor means, andsaid first mixer means including said rotor means and means directingthe first and second binder components to said rotor means to bedispersed thereby.

Other objects and a fuller understanding of the invention may be had byreferring to the following description and claims, taken in conjunctionwith the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a simplified embodiment ofthe present invention showing a vertical sectional view of a foundrymachine for mixing a mold material component and a binder component;

FIG. 2 is a vertical sectional view of a variation of the rotor meanswhich is compatible for use with the invention shown in FIGS. 1 and 4;

FIG. 3 is a vertical sectional view of still an additional variation ofthe rotor means which is compatible for use with the invention shown inFIGS. 1 and 4;

FIG. 4 is the preferred embodiment of the present invention showing avertical sectional view of a foundry machine;

FIG. 5 is an isometric view of a variation of the rotor means usablewith the invention shown in FIGS. 1 and 4; and,

FIG. 6 is an isometric view of a variation of the rotor means which iscompatible with the invention shown in FIGS. 1 and 4.

DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. 1 shows a simplifiedembodiment of a foundry machine for mixing a mold material component anda first and a second binder component 61 and 62, respectively, whichincludes a discharge means shown generally as 10 for the mold materialcomponent 14, a first mixer means 11 to mix two of the components and asecond mixer means 12 to mix a third component with the aforementionedtwo components. The discharge means 10 includes a housing 24 and asurface 25 established relative to the housing 24 to form a channel 28therebetween. FIG. 1 shows the channel 28 being half occupied by themold material component 14. The mold material component 14 is shown assand but can be any material suitable for molds or cores in a foundryprocess. The channel 28 also includes a discharge opening 26 for thedischarge of the mold material component 14. A loading opening 27 isestablished on one end of the generally vertical channel 28 for loadingthe mold material component 14 into the discharge means 10. Thedischarge opening 26 is shown to be substantially annular about an axisof symmetry 36 of the housing 24 and includes gate means 29 to open andclose the discharge opening 26..An actuator 30 fixed to the housing 24moves the gate means 29 to close or open the discharge opening 26 uponthe command of an operator.

The first mixer means 11 includes a rotor means which is mounted belowthe discharge means 10 on a substantially vertical shaft 34 and rotatedby motor means 35. The first mixer means 11 also includes means 18, 19directing the first and second binder components 61, 62 to said rotormeans 15 to be dispersed thereby. The directing means 18, 19 include afirst and a second reservoir 21 and 22 which are interconnected byconduits or connector means 37, 38, 39 and 40 with a first and a secondpumping means 31 and 32 and a first and a second valve means 41 and 42for the first and second binder components 61 and 62, respectively. Eachof the valve means 41 and 42 has an actuated and an unactuated position.The'valve means 41 and 42 are shown as three way valve means in theactuated position. First and second component tubes 51 and 52 direct thefirst and second binder components 61 and 62 to the rotor means 15.

The second mixer means 12 includes a director means 45 directing themold material component 14 emanating from the discharge means 10 tosubstantially envelop the rotor means 15. The director means 45 divrects the mold material component 14 which is shown falling from thedischarge openings 26 by action of gravity to pass in proximity to therotor means 15 to be mixed with the binder components dispersed by therotor means 15. The fall of the mold material component 14 is notrestricted by sliding on any adjacent surface. Thus, the mold materialcomponent is freely falling by action of gravity. The prior art mixingmachines generally had the material component sliding down an inclinedsurface during the mixing process. This caused packing of the materialcomponent which inhibited coating component penetration and mixing. Thisalso caused turbulent flow and material build up of the materialcomponent on the inclined surface. The director means 45 also directsthe mold material component 14 to converge after passing the rotor means15.

The director means 45 is attached to a bracket 46 having a slot 47 andsecured to the housing 24 by a bolt 48. The slot 47 in the bracket 46allows a vertical movement, as shown by the arrow in FIG. 1 of thedirector means 45, to vary the convergence of the mold materialcomponent 14. A shield 54 prevents any of the dispersed bindercomponents from the rotor means 15 from emanating outside the immediatearea of the foundry mixing machine.

The disclosed invention shown in FIG. 1 operates in the followingmanner. The first and the second binder components 61 and 62 of amulti-component binder are stored in the first and second reservoirs 21and 22, respectively. The mold material component 14 is loaded into thechannel 28 of the discharge means 10 through the loading opening 27.This loading process can either be a continuous process or the channel21 can be of a size large enough to hold a sufficient amount of moldmaterial component 14 for a given mixing application. The gate means 29can be kept in a closed position by the actuator 30 to allow the moldmaterial component 14 to be loaded. The first and second valve means 41and 42 are set in the unactuated position by rotating the valve means 90in the direction of the adjacent respective arrows. When the first andsecond pumping means 31 and 32 are energized, the first pumping means31circnlates the first binder component 61 from the reservoir 21 byconnector means 37 to the first valve means 41 and back through theconnector means 39 to the first reservoir 21. The second bindercomponent 62 is pumped from the second reservoir 22 by the secondpumping means 32 through connector means 38 to the valve means 42 andreturns to the second reservoir 22 by connector means 40. Thiscirculation insures that a fresh supply of binder component underpressure is available at the first and second valve means 41 and 42 atany given time. This circulation also prevents any premature curingwhich might take place within the connector means, pumping means orvalve means. When'the motor means 35 is energized, the shaft 34 and therotor means 15 rotate at a very high speed. Typically this rotation canbe between 5,000 RPM and 15,000 RPM. When the rotor means 15 hasachieved a suitable revolution rate, the first and second valve means 41and 42 are rotated into the actuated position, as shown, by an operator.This allows the first and second pumping means 31 and 32 to pump thefirst and second binder components 61 and 62 from the first and secondreservoirs 21 and 22 through the first and second component tubes 51 and52, respectively, into the rotating rotor means 15.

The rotor means 15 includes a first rotor surface means 65 having rotoropening means 60 therein. The rotor opening means 60 have a substantialvectorial dimensional component parallel to the axis 36. The rotoropening means 60 are shown as vertical slots having a long lengthrelative to the width thereof. However, the rotor opening means 60 couldbe a series of small openings which in combination produce an openinghaving a substantial vectorial component parallel to the axis 36 ofrotation of the rotor means 15. The rotor means 15 also includes asecond rotor surface means 66 having a substantial vectorial componentnormal to the axis 36. The rotor means 15 inFlG. l is shown as acontainer in which the first rotor surface means 65 is the side of thecontainer and the second rotor surface means 66 is the bottom of thecontainer.

The rotating rotor means is shown as a two-level rotor means having anupper level 57 and a lower level 58 separated by a separator 59 andsecured to the shaft 34 by a nut 69. The rotor means is removable to aidin cleaning and to install rotor means of different design asillustrated in FIGS. 2, 3, 5 and 6. The separator 59 is also a rotorsurface having a substantial vectorial component normal to the axis ofshaft 34, and as such is part of the second rotor surface means 66. Thefirst binder component 61 is directed from the first component tube 51into the upper level 57 whereas the second binder component 62 isdirected from the second component tube 52 into the lower level 58. Therotation of the rotor means 15 creates a centrifugal force to move thefirst and second binder components 61 and 62 (which are) on the firstrotor surface means 65 to a majority of the area of the rotor openingmeans 60. The binder components cover a majority of the area of therotor opening means 60 and are thrown out by the action of centrifugalforce. Thus, the rotation of the rotor means 15 forces the first andsecond binder components 61 and 62 through the rotor opening means 60 tobe dispersed or atomized in proximity to the rotor means 15. The firstbinder component 61 is dispersed as shown by the arrows designated 61,whereas the second binder component 62 is dispersed as shown by thearrows designated 62. When the atomization process by the rotor means 15is established, the operator opens the gate means 29 to establish theflow of the mold material component 14 directed by the director means 45to pass in proximity to the rotating rotor means 15. As the moldmaterial component 14 passes the rotor means 15, the first mixing means11 mixes the first binder component 61 with the mold material component14 at an area designated 71 and as the mold material component 14continues to fall, the second mixing means 12 mixes the mixture of themold material component 14 and the first binder component 61 with thesecond binder component 62 at an area designated 72. The process ofmixing by the first and second mixing means 11 and 12 at areas 71 and72, respectively, takes place when the mold material component is in afreely falling condition. This allows a greater binder penetrationthrough the falling material and produces a more complete mixing. Inthis embodiment, the first and second binder components 61 and 62 arenot directly mixed with each other prior to mixing with the moldmaterial component 14 but the mold material component 14 is mixed withthe first binder component 61 and is subsequently mixed with the secondbinder component 62. For example, the first binder component 61 can be aresin which is mixed with the mold material component 14, and the secondbinder component 62 can be a catalyst which is mixed with the mixture ofthe resin and the mold material component 14 to avoid premature curingof the three component mixture. The foregoing mixing process can be acompletely automatic process requiring an operator to only start andstop themachine.

FIGS. 2, 3, 5 and 6 show modified versions of the rotor means 15 whichare compatible for use with the invention shown in FIG. 1. The rotormeans in FIGS. 1 and 4 can be removed by removal of the nut 69 andeither of the rotor means 15A or 15B, 15C, 15D and 15E can be installed.FIGS. 2 and 3 illustrate the first and second component tubes 51 and 52and a portion of the mold material component 14 which is falling inproximity to the rotating rotor means 15. Each of the rotor means inFIGS. 2 and 3 has a first rotor surface means 65, designated 65A and65B, and a second rotor surface means 66, designated 66A and 66B,respectively. The second rotor surface means 66A in FIG. 2 is shown asthe bottom of a container with the first rotor surface means 65A beingthe side of the container. The second rotor surface means 668 in FIG. 3

includes a member 79 located near the top of the rotor means 15B towhich the first and second binder components 61 and 62 are directed.

FIGS. 2 and 3 illustrate means directing the first and second bindercomponents 61 and 62 to the first rotor surface means 65A or 658. Thismeans includes directing the first and second binder components 61 and62 to the second rotor surface means 66A or B to be moved by action ofthe rotating rotor means 15 to the first rotor surface means 65. Thus,in FIGS. 2 and 3, the first and second binder components 61 and 62 willdrop to the second rotor surface means 66A or B to be moved by action ofthe rotating rotor means 15A or B to cover the first rotor surface means65A or B and a majority of the area of the rotor opening means 60.

The means directing the binder components 61 and 62 to the first rotorsurface means 65 also includes directing the first and second bindercomponents 61 and 62 by the first and second tubes 51 and 52 to drop orflow directly onto the first rotor surface means 65A or B. In such acase, the bottom of the container can be effectively eliminated toneutralize any updraft created by air filling into the rotor means 15.Such an updraft is caused by a partial vacuum created within the rotormeans 15 due to the dispersion of the atmosphere therein through therotor opening means 60.

In the embodiments shown in FIGS. 2 and 3, the first mixer means 11mixes the first binder component 61 with the second binder component 62within the rotor means 15. The mixture of the first and second bindercomponents 61 and 62 is then dispersed through the rotor opening means60 for further mixing of the two dispersions wherein the second mixermeans 12 mixes the mold material component 14 with the mixed bindercomponents 61 and 62 at area designated 82.

In the embodiment shown in FIG. 1, the first mixer means 11 mixes thefirst binder components 61 with the mold material component 14 and thesecond mixer means 12 mixes the mixture of the first binder component 61and the mold material component 14 with the second binder component 62.The installation of a rotor means illustrated in FIGS. 2, 3, 4 and 5will transform FIG. 1 such that the first mixer means 11 will mix thefirst and second binder components 61 and 62 and the second mixer means12 will mix the mixture of the binder components with the mold materialcomponent 14. In addition to these two combinations of the first andsecond mixer means 11 and 12, a third combination is possible whereinthe first and second binder components 61 and 62 are dispersedseparately as shown in FIG. 1 but mixed with one another in closeproximity to the rotor means 15 and proceed to be dispersed as a mixtureto mix with the mold material component 14. Each of these methods ofmixing are useful to accommodate for differences in the physicalcharacteristics of the mold material components and the bindercomponents. Each of these methods of mixing is included within the scopeof this invention.

The rotor opening means 60 can be small perforations or slots as shownin FIG. 1, to increase the vertical dispersion of the first and secondcomponent binders 61 and 62. The slots may be very thin, for example,0.005 inches, up to 0.250 inches in thickness and having a lengthcommensurate with the sides of the rotor means 15. The slots in therotor means 15 can be substantially vertical or can be at an angle withrespect to the rotating axis 36 depending upon the specific applicationand materials used. In most applications, a plurality of slots will bepresent in the rotor means 15 to insure that the binder components areproperly dispersed into a fine dispersion to produce complete mixing.The movement of the director means 45 enables the operator to somewhatvary the convergence or pattern of the falling mold material component14 after passing by the rotor means 15. This enables the operator todirectly fill a mold or core box after passing by the rotor means 15without being directed by a funnel or an additional deflection plate.The additional deflection plate also prevents the falling material frombeing in a true free falling condition. The free falling condition isdesirable since the amount of the falling material per unit airspace inproximity to the rotor means 15 is reduced allowing a more complete.penetration and mixing by the binder components. This also eliminatesthe problem of clogging in funnels directing mold material after themold material has been saturated with a binder. The shield 54 preventsthe dispersion of the first and second binder components into theimmediate atmosphere when there is no flow of the mold materialcomponent 14. The shield 54 does not support the mold material component14 during the mixing process.

The preferred embodiment FIG. 4 illustrates a foundry machine for mixingthe mold material component 14 and the first and second bindercomponents 61 and 62, respectively, which is a more refined version ofthe foundry machine shown in FIG. 1. The discharge means 10 of thefoundry machine shown in FIG. 4 is substantially identical to thedischarge means 10 shown in FIG. 1 comprising the housing 24, thesurface 25, the discharge opening 26 and the gate means 29. The actuator30 lifts the gate means 29 in a manner similar to that shown in FIG.1.-The foundry machine shown in FIG. 4 includes a support 100 mounted tothe housing 24 having a screw 102 which is adjustable by a handadjustment 104. The screw 102 adjusts the maximum travel of the gatemeans 29 to vary the size of the discharge opening 26.

A second housing 85 is attached by bolts 86 and 87 to the dischargemeans 10. The housing 85 includes air valves 88 and 89 which areconnected by the tubes 90 and 91 to an air compressor pump 92. The aircompressor pump 92 is shown for the sake of simplicity to be within thehousing 85 but typically would be found without the housings 24 and 85of the foundry machine. The tubes 90 and 91 can be established betweenthe channel 28 as the conduit tubes 37-40.

The foundry machine shown in FIG. 4 also includes director means whichcomprises first director means 45A and a second director means 45B. Thefirst director means 45A directs the falling mold material component 14to converge towards the axis of symmetry 36 whereas the second directormeans 458 causes the mold material component to slightly diverge fromthe axis of symmetry 36 to be free-falling in a substantially verticaldirection at mixing points 82. The first director means 45A forms anangle relative to the axis 36 having a value between 20 and whereas thesecond director means 458 forms an angle relative to axis 36 having avalue between 5 and 15. Experiments by the inventor indicate that 40 and10 for the first and second director means 45A and 458, respectively,are the optimum for most mold material components. Rotor means havingdiameters between 2.0 and 6.0 inches, having a surface speed within arange of 3000 to 16,000 feet per minute have been found to be effective.

A shield 54A is attached to the director means 45A and includes a thirddirector means 54B to direct the mold material component 14 to convergeto the axis of symmetry 36. An exit cone 95 is suspended by a support 92which is attached to the third director means 548 to produce an annularopening at the base of the third director means 54B. A vibrating means107 is connected by connectors 111 to a support 110 which is fixedrelative to the housing 24. The vibrating means is attached to aconnector 108 to vibrate the third director means 548.

The rotor means 15C is attached to the shaft 34 by the nut 69. The rotormeans 15C includes a first rotor surface means C and a second rotorsurface means 66C. The first rotor surface means 65C contains rotoropening means 60 which are shown as a series of holes in the first rotorsurface means 65C having a substantial vectorial component parallel tothe axis 36. The first and second binder components 61 and 62,respectively, are mixed by the first mixer means 11 in the rotor means15C and are dispersed through the rotor opening means 60 to mix with themold material component 14 at mixing points 82. The operation of therotor means 15C is similar to the operation of the structure shown inFIG. 2. However, any of the rotor means illustrated in FIGS. 1-3 arecompatible with the invention shown in FIG. 4.

The preferred embodiment shown in FIG. 4 has many advantages over thesimplified embodiment shown in FIG. 1. The preferred embodiment is ableto accommodate a wide range of materials used by a foundry in a mold orcore making process. For an example, viscosity ranges of bindercomponents between 0.8 and 6.0 on the stokes scale can be encountered.In addition, a wide range in particle size of the mold materialcomponent 14 can be used with the invention shown in FIG. 4.

FIG. 4 illustrates the mixing of a first and second binder component 61and 62 with a mold material component 14 which has a very fine particlesize. The fact that the mold material component 14 has a fine particlesize is emphasized by the fact that the stream of falling mold materialcomponent diverges at points 82 due to the first and second bindercomponents 61 and 62 striking the falling mold material component 14.The mixing of a mold material component 14 having a small particle sizerequires the third director means 548 to direct the falling moldmaterial component to converge towards the axis of symmetry 36.

.However, the mixing is accomplished when the mold material component 14is freely falling. The exit cone prevents any of the mold materialcomponent 14 which has not been coated with the binder components 61 and62 to exit without being within the stream of mold' material component14. Any particles that re-' main uncoated will strike the exit cone 95and will fall into the stream of mold material component 14 and will bemixed thereby. The shield 54A and the third director means 54B inaddition to the exit cone 95 can be made of or coated with a smoothsurface to inhibit the mixed mold material component 14 and the firstand second binder components 61 and 62 from sticking thereon. This canalso be accomplished by covering these surfaces 54A, 54B and 95 with adisposable liner. The shield 54A is shown covered with a disposableliner 94 to allow rapid cleaning. The vibrating means 107 causesvibration of the third director means 548 to inhibit the mixed moldmaterial and binder components from sticking to the third director means54B.

The air jets 83 and 84 aid in insuring a uniform mixing of thecomponents during the initial and final stages of a given mixingprocess. For example, assume that the gate means 29 is closed, the rotormeans 15C is rotating and the first and second binder components 61 and62 are being pumped into the rotor means 15C. Prior to opening the gatemeans 29, air jets controlled by the air jets 88 and 89 are energizedfor a duration between a fraction of a second and several secondscreating a partial vacuum in proximity to the rotor means 15C. As thegate means 29 is opened by the actuator 30, the flow of mold materialcomponent 14 does not start immediately but starts as a small amount andincreases in flow rate into a stream in accordance with the manner inwhich the gate means 29 opens the discharge openings 26. During theperiod of time when a small amount of mold material component 14 isfalling, the air jets 83 and 84 cause the mold material components 14 tofall near the rotor means 15C as the established streams shown in FIG.4. This partial vaccum is sustained after the stream of mold materialcomponent is established by action of the rotor means 15C. Upon closingthe discharge opening means with the gate means 29, the stream of moldmaterial component will again be reduced. The air jets 83 and 84 will beagain energized to maintain the partial vacuum causing the substantiallyreduced stream to be mixed in a manner similar to the establishedstream. Thus the air jets 83 and 84 insure that the initial and finalflow of mold material component 14 will be mixed as uniformly as theintermediate flow.

FIG. illustrates a rotor means D connected to the shaft 34 which iscompatible with the foundry machines illustrated in FIGS. 1 and 4. Rotormeans 15D includes a first rotor surface means 65D and a second rotorsurface means 66D. The first rotor surface means 65D includes rotoropening means 60 illustrated as holes drilled in the first rotor surfacemeans 65D. These holes could typically be from 0.010 to 0.060 inches indiameter and spaced from one another by 1 to 6.

The second rotor surface means 66D includes the bottom surface of therotor means and the plurality of protrusions 121-124 extendingperpendicularly from the axis of rotation which is the shaft 34. Theprotrusions 121-124 distribute the first and second binder component 61and 62 emanating from the first and second component tubes 51 and 52,respectively, over the entire first rotor surface means 65D to produce auni-. form vertical dispersion.

FIG. 6 illustrates a rotor means 15E which is similar in construction tothe rotor means shown in FIG. 5. The

rotor means 15E includes a first rotor surface means 6515 and a secondrotor surface means 66E. The first rotor surface means 65E includesrotor opening means 60 and the second rotor surface means 66E includesthe bottom of the rotor means 15E and an inner rotor projection 130. Theinner rotor surface projection 130 forms an acute angle with the axis ofrotation and rotates with shaft 34 to aid in distributing the first andsecond binder components 61 and 62 uniformly over the first rotorsurface means 65E. The rotor means 15D and 15B illustrated in FIGS. 5and 6 are compatible with the foundry machines illustrated in FIGS. 1and 4.

The preferred embodiment FIG. 4 illustrates a foundry mixing machinecapable of handling a wide variety of mold material components andbinder components. The second housing 85 effectively creates a smallerannular opening between the director means 45A and 45B to produce afalling curtain of mold material component 14 of a given thickness witha substantially reduced flow rate. The amount of mold material component14 which is flowing per unit time at a given curtain thickness is afunction of the radius of the curtain from the axis 36. The directormeans 45A and 45B substantially reduce the diameter of the falling moldmaterial component 14 to accommodate for lower flow rates of moldmaterial component 14. In addition the third director means 54Bconverges the mold material component such that it can be poureddirectly into a mold or a core box.

Experiments by the inventor have demonstrated that the mixture of moldmaterial component 14 and binder components 61 and 62 has a greaterfluffiness than a similar mixture achieved by the prior art mixingprocesses. Mold material and binder components mixed by the disclosedinvention have as much as 18 percent lower weight per unit volume thansimilar materials mixed by the prior art processes. The lower densityallows an easier flow of the mixture and enables more exact mold andcore forms to be made. The mixing process disclosed in this inventiondoes not damage the mold material component by grinding and breaking thematerial as commonly experienced in the prior art processesincorporating internal impellers and the like. Accordingly, the moldmaterial component can be reused by buming off the binder componentsproducing a more economical foundry process. Finally, experiments by theinventor indicate that the foundry mixing machines illustrated in FIGS.1 and 4 do not discriminate between small and large particles of moldmaterial component as was found in the prior art machines. Thisdisadvantage of the prior art machines produced variations in strengthof the molds and cores which could cause defective castings resulting insevere economic losses.

In a foundry core or mold-making process wherein the products of thefoundry require a limited selection of mold material and bindercomponents, the invention shown in FIG. 1 is suitable for suchapplications. However, in the foundry wherein a variety of mold materialcomponents are used having a wide variety of characteristics, theinvention shown in FIG. 4 is more suitable for such application.

The present disclosure includes that contained in the appended claims,as well as that of the foregoing description. Although this inventionhas been described in its preferred form with a certain degree ofparticularity, it is understood that the present disclosure of thepreferred form has been made only by way of example and that numerouschanges in the details of construction and the combination andarrangement of parts may be resorted to without departing from thespirit and the scope of the invention as hereinafter claimed.

What is claimed is:

l. A foundry machine for mixing a mold material component and a binderhaving a first and a second component, comprising in combination,

discharge means for the mold material component,

first mixer means to mix two of the components,

second mixer means to mix a third component with the aforementioned twocomponents,

rotatable rotor means,

said second mixer means including director means directing the moldmaterial emanating from said discharge means to substantially envelopsaid rotor means,

and said first mixer means including said rotor means and meansdirecting the first and second binder components to said rotor means tobe dispersed thereby.

2. A foundry machine as set forth in claim 1, wherein said dischargemeans includes;

a housing,

a surface established relative to said housing forming a channeltherebetween,

and said channel having a discharge opening for the discharge of themold material component.

3. A foundry machine as set forth in claim 2, wherein said channelincludes a loading opening for loading the mold material component.

4. A foundry machine as set forth in claim 2, including gate means forsaid discharge opening to open and close said opening.

5. A foundry machine as set forth in claim 2, wherein said channel isgenerally vertical,

and said discharge opening is substantially annular.

6. A foundry machine as set forth in claim 1, wherein said rotormeans ismounted below said discharge means on a substantially vertical shaft androtated by motor means.

7. A foundry machine as set forth in claim 6, wherein said directormeans includes first and second director means,

said first director means converging the mold material component andforming an angle relative to said vertical shaft having a value between20 and 60,

and said second director means diverging the mold material component andforming an angle relative to said vertical shaft having a value betweenand 15.

8. A foundry machine as set forth in claim 1, wherein said rotor meanshas a bottom and sides and rotor opening means therein.

9. A foundry machine as set forth in claim 8, wherein said rotor openingmeans includes a slot opening in the side of said rotor means.

10. A foundry machine as set forth in claim 8,

wherein said rotor means is symmetrical about an axis of rotation.

11. A foundry machine as set forth in claim 8, wherein the rotation ofsaid rotor means causes the first and second binder components and theatmosphere within said rotor means to be forced through said rotoropening means by action of centrifugal force to create dispersion ofsaid first and second binder components in proximity to said rotor meansto enable mixing with the mold material component by said second mixermeans.

12. A foundry machine as set forth in claim 1, wherein said first mixermeans mixes the first and second binder components and said second mixermeans mixes the mold material component with the mixed bindercomponents.

13. A foundry machine as set forth in claim 1, wherein said first mixermeans mixes the first binder component with the mold material componentand said second mixer means mixes the second binder component with themixed first component and the mold material component.

14. A foundry machine as set forth in claim 1, wherein said meansdirecting the first and second binder components to said rotor meansincludes;

a first and a second reservoir,

first and second pumping means,

first and second valve means,

and connector means interconnecting said first and second reservoirs,said first and second pumping means and said first and second valvemeans for said first and second binder components, respectively.

15. A foundry machine as set forth in claim 14, wherein each of saidvalve means has an actuated and an unactuated position and said firstand second pumping means circulates the first and second bindercomponents between said first and second valve means and said first andsecond reservoirs, respectively, when said valve means are in theunactuated position and said first and second pumping means pumps thefirst and second binder components, respectively, to said rotor meanswhen said first and second valve means are in the actuated position.

16. A foundry machine as set forth in claim 1, wherein said directormeans includes directing the mold material component emanating from saiddischarge means to pass in proximity to said rotor means to be mixedwith the binder components dispersed by said rotor means.

17. A foundry machine as set forth in claim 16, wherein said directormeans includes directing the mold material component to converge afterpassing said rotor means.

18. A foundry machine as set forth in claim 1, wherein the mold materialcomponent emanating from said discharge means includes the mold materialcomponent falling by action of gravity.

19. A foundry machine as set forth in claim 1, wherein said directormeans includes a first and a second director means.

20. A foundry machine as set forth in claim 19, wherein said firstdirector means directs the mold material component to converge and saidsecond director means directs the mold material component to divergerelative to said rotor means.

21. A foundry machine as set forth in claim 20, including a thirddirector means to converge the mold material component.

22. A foundry machine as set forth in claim 21, including vibrator meansconnected to said third deflector means to vibrate said third deflectormeans.

23. A foundry machine as set forth in claim 1, including air jet meansestablishing a partial vacuum in proximity to said rotor means toestablish the mold material component to substantially envelop saidrotor means.

24. A foundry machine for mixing a mold material component and a binderhaving a first and second component comprising in combination,

a housing for the mold material component,

a surface established relative to said housing forming a channeltherebetween,

said channel having a discharge opening for the discharge of the moldmaterial component,

first mixer means to mix two of the components,

second mixer means to mix a third component with the aforementioned twocomponents,

rotatable rotor means,

director means,

said first mixer means including;

said rotor means mounted below said discharge opening on a substantiallyvertical shaft and rotated by motor means,

means directing the first and second binder components to said rotormeans to be dispersed thereby,

and said second mixer means including said director means directing themold material component falling from said discharge opening tosubstantially envelop said rotor means to be mixed with the bindercomponents dispersed by said rotor means.

25. A foundry machine for mixing a mold'material component and a binderhaving a first and second component, comprising in combination,

discharge means for the mold material component,

first mixer means to mix two of the components,

second mixer means to mix a third component with the aforementioned twocomponents,

rotatable rotor means,

said second mixer means including director means directing the moldmaterial component emanating from said discharge means to substantiallyenvelop said rotor means,

said first mixer means including said rotor means and means directingthe first and second binder compo nents to said rotor means to bedispersed thereby,

said means directing the first and second binder components to saidrotor means includes;

a first and a second reservoir interconnected with first and secondpumping means a first and second valve means for said first and secondbinder components, respectively,

and said valve means each having an actuated and an unactuated positionand said first and second pumping means circulates the first and secondbinder components between said first and second valve means and saidfirst and second reservoirs, respectively, when said valve means are inthe unactuated position and said first and second pumping means pumpsthe first and second binder components, respectively, to said rotormeans when said first and second valve means are in the actuatedposition.

26. A foundry machine for mixing a mold material component and a binderhaving a first and second component comprising in combination,

a housing for the mold material component,

a surface established relative to said housing forming a generallyvertical channel therebetween,

said channel having a loading opening and a substantially annulardischarge opening for the loading and discharge of the mold materialcomponent, respectively,

gate means for said discharge opening to open and close said dischargeopening,

first mixer means to mix two of the components.

second mixer means to mix a third component with the aforementioned twocomponents,

rotatable rotor means,

director means,

said first mixer means including;

said rotor means mounted below said discharge opening on a substantiallyvertical shaft and rotated by motor means,

said rotor means having a bottom and sides with rotor opening meanstherein,

means directing the first and second binder components to said rotormeans to be dispersed thereby,

said means directing the first and second binder com ponents to saidrotor means including;

a first and a second reservoir interconnected with first and secondpumping means and first and sec ond valve means for said first andsecond binder components, respectively,

said valve means each having an actuated and an unactuated position andsaid first and second pumping means circulates the first and secondbinder components between said first and second valve means and saidfirst and second reservoirs, respectively, when said valve means are inthe unactuated position and said first and second pumping means pumpsthe first and second binder components, respectively, to said rotormeans when said first and second valve means are in the actuatedposition,

and said second mixer means including said director means directing themold material component falling from said discharge opening tosubstantially envelop said rotor to be mixed with the binder componentsdispersed by said rotor means and to substantially converge afterpassing said rotor means.

27. A foundry machine for mixing a mold material component and a bindercomponent, comprising in combination,

rotor means having an axis of rotation and a first rotor surface,

rotor opening means in. said first rotor surface means having asubstantial vectorial component parallel to said axis,

means directing the binder component to said first rotor surface means,

means rotating said rotor means to move the binder component which is onsaid first rotor surface means to a majority of the area of said rotoropening means and to force the binder component through said rotoropening means to form a dispersion,

and director means directing the mold material component to saiddispersion to mix with the binder component.

28. A foundry machine as set forth in claim 27,

wherein said axis is substantially vertical.

29. A foundry machine as set forth in claim 27, wherein said rotoropening means includes a slot having a long length relative to the widththereof.

30. A foundry machine as set forth in claim 27, wherein said meansdirecting the binder component to said first rotor surface meansincludes,

a second rotor surface means having a substantial vectorial componentnormal to said axis,

and means directing the binder component to said second rotor surfacemeans to be moved by action of said rotating rotor means to said firstrotor surface means.

31. A foundry machine as set forth in claim 30, wherein said first rotorsurface means includes the side of a container and said second rotorsurface means includes the bottom of said container.

32. A foundry machine as set forth in claim 30, wherein said secondrotor surface means includes a plurality of projections extendingperpendicularly from said axis of rotation 33. A foundry machine as setforth in claim 32, wherein said projections project from differentlocations along said axis of rotation.

34. A foundry machine as set forth in claim 30, wherein said secondrotor surface means includes an inner rotor projection surface formingan acute angle with said axis of rotation.

35. A foundry machine for mixing a mold material component and a bindercomponent, comprising in combination,

rotor means having a first rotor surface with rotor opening meanstherein, said rotor opening means having a major vectorial componentparallel to the axis of rotation of said rotor means, means directingthe binder component to said rotor means, director means directing themold material component to substantially envelop said rotor means, andmeans rotating said rotor means to disperse the binder component throughsaid rotor opening means to form a dispersion to enable mixing of thecomponents only when the mold material component is freely falling byaction of gravity. 36. A foundry machine as set forth in claim 35,wherein said director means includes director means directing the moldmaterial component to converge after passing said rotor means.

1. A foundry machine for mixing a mold material component and a binderhaving a first and a second component, comprising in combination,discharge means for the mold material component, first mixer means tomix two of the components, second mixer means to mix a thIrd componentwith the aforementioned two components, rotatable rotor means, saidsecond mixer means including director means directing the mold materialemanating from said discharge means to substantially envelop said rotormeans, and said first mixer means including said rotor means and meansdirecting the first and second binder components to said rotor means tobe dispersed thereby.
 2. A foundry machine as set forth in claim 1,wherein said discharge means includes; a housing, a surface establishedrelative to said housing forming a channel therebetween, and saidchannel having a discharge opening for the discharge of the moldmaterial component.
 3. A foundry machine as set forth in claim 2,wherein said channel includes a loading opening for loading the moldmaterial component.
 4. A foundry machine as set forth in claim 2,including gate means for said discharge opening to open and close saidopening.
 5. A foundry machine as set forth in claim 2, wherein saidchannel is generally vertical, and said discharge opening issubstantially annular.
 6. A foundry machine as set forth in claim 1,wherein said rotor means is mounted below said discharge means on asubstantially vertical shaft and rotated by motor means.
 7. A foundrymachine as set forth in claim 6, wherein said director means includesfirst and second director means, said first director means convergingthe mold material component and forming an angle relative to saidvertical shaft having a value between 20 and 60*, and said seconddirector means diverging the mold material component and forming anangle relative to said vertical shaft having a value between 5* and 15*.8. A foundry machine as set forth in claim 1, wherein said rotor meanshas a bottom and sides and rotor opening means therein.
 9. A foundrymachine as set forth in claim 8, wherein said rotor opening meansincludes a slot opening in the side of said rotor means.
 10. A foundrymachine as set forth in claim 8, wherein said rotor means is symmetricalabout an axis of rotation.
 11. A foundry machine as set forth in claim8, wherein the rotation of said rotor means causes the first and secondbinder components and the atmosphere within said rotor means to beforced through said rotor opening means by action of centrifugal forceto create dispersion of said first and second binder components inproximity to said rotor means to enable mixing with the mold materialcomponent by said second mixer means.
 12. A foundry machine as set forthin claim 1, wherein said first mixer means mixes the first and secondbinder components and said second mixer means mixes the mold materialcomponent with the mixed binder components.
 13. A foundry machine as setforth in claim 1, wherein said first mixer means mixes the first bindercomponent with the mold material component and said second mixer meansmixes the second binder component with the mixed first component and themold material component.
 14. A foundry machine as set forth in claim 1,wherein said means directing the first and second binder components tosaid rotor means includes; a first and a second reservoir, first andsecond pumping means, first and second valve means, and connector meansinterconnecting said first and second reservoirs, said first and secondpumping means and said first and second valve means for said first andsecond binder components, respectively.
 15. A foundry machine as setforth in claim 14, wherein each of said valve means has an actuated andan unactuated position and said first and second pumping meanscirculates the first and second binder components between said first andsecond valve means and said first and second reservoirs, respectively,when said valve means are in the unactuated position and said first andsecond pumping means pumps the first and second binder components,respectively, to said rotor means when said first and second valve meaNsare in the actuated position.
 16. A foundry machine as set forth inclaim 1, wherein said director means includes directing the moldmaterial component emanating from said discharge means to pass inproximity to said rotor means to be mixed with the binder componentsdispersed by said rotor means.
 17. A foundry machine as set forth inclaim 16, wherein said director means includes directing the moldmaterial component to converge after passing said rotor means.
 18. Afoundry machine as set forth in claim 1, wherein the mold materialcomponent emanating from said discharge means includes the mold materialcomponent falling by action of gravity.
 19. A foundry machine as setforth in claim 1, wherein said director means includes a first and asecond director means.
 20. A foundry machine as set forth in claim 19,wherein said first director means directs the mold material component toconverge and said second director means directs the mold materialcomponent to diverge relative to said rotor means.
 21. A foundry machineas set forth in claim 20, including a third director means to convergethe mold material component.
 22. A foundry machine as set forth in claim21, including vibrator means connected to said third deflector means tovibrate said third deflector means.
 23. A foundry machine as set forthin claim 1, including air jet means establishing a partial vacuum inproximity to said rotor means to establish the mold material componentto substantially envelop said rotor means.
 24. A foundry machine formixing a mold material component and a binder having a first and secondcomponent comprising in combination, a housing for the mold materialcomponent, a surface established relative to said housing forming achannel therebetween, said channel having a discharge opening for thedischarge of the mold material component, first mixer means to mix twoof the components, second mixer means to mix a third component with theaforementioned two components, rotatable rotor means, director means,said first mixer means including; said rotor means mounted below saiddischarge opening on a substantially vertical shaft and rotated by motormeans, means directing the first and second binder components to saidrotor means to be dispersed thereby, and said second mixer meansincluding said director means directing the mold material componentfalling from said discharge opening to substantially envelop said rotormeans to be mixed with the binder components dispersed by said rotormeans.
 25. A foundry machine for mixing a mold material component and abinder having a first and second component, comprising in combination,discharge means for the mold material component, first mixer means tomix two of the components, second mixer means to mix a third componentwith the aforementioned two components, rotatable rotor means, saidsecond mixer means including director means directing the mold materialcomponent emanating from said discharge means to substantially envelopsaid rotor means, said first mixer means including said rotor means andmeans directing the first and second binder components to said rotormeans to be dispersed thereby, said means directing the first and secondbinder components to said rotor means includes; a first and a secondreservoir interconnected with first and second pumping means a first andsecond valve means for said first and second binder components,respectively, and said valve means each having an actuated and anunactuated position and said first and second pumping means circulatesthe first and second binder components between said first and secondvalve means and said first and second reservoirs, respectively, whensaid valve means are in the unactuated position and said first andsecond pumping means pumps the first and second binder components,respectively, to said rotor means when said first and second valve meansare in the Actuated position.
 26. A foundry machine for mixing a moldmaterial component and a binder having a first and second componentcomprising in combination, a housing for the mold material component, asurface established relative to said housing forming a generallyvertical channel therebetween, said channel having a loading opening anda substantially annular discharge opening for the loading and dischargeof the mold material component, respectively, gate means for saiddischarge opening to open and close said discharge opening, first mixermeans to mix two of the components, second mixer means to mix a thirdcomponent with the aforementioned two components, rotatable rotor means,director means, said first mixer means including; said rotor meansmounted below said discharge opening on a substantially vertical shaftand rotated by motor means, said rotor means having a bottom and sideswith rotor opening means therein, means directing the first and secondbinder components to said rotor means to be dispersed thereby, saidmeans directing the first and second binder components to said rotormeans including; a first and a second reservoir interconnected withfirst and second pumping means and first and second valve means for saidfirst and second binder components, respectively, said valve means eachhaving an actuated and an unactuated position and said first and secondpumping means circulates the first and second binder components betweensaid first and second valve means and said first and second reservoirs,respectively, when said valve means are in the unactuated position andsaid first and second pumping means pumps the first and second bindercomponents, respectively, to said rotor means when said first and secondvalve means are in the actuated position, and said second mixer meansincluding said director means directing the mold material componentfalling from said discharge opening to substantially envelop said rotorto be mixed with the binder components dispersed by said rotor means andto substantially converge after passing said rotor means.
 27. A foundrymachine for mixing a mold material component and a binder component,comprising in combination, rotor means having an axis of rotation and afirst rotor surface, rotor opening means in said first rotor surfacemeans having a substantial vectorial component parallel to said axis,means directing the binder component to said first rotor surface means,means rotating said rotor means to move the binder component which is onsaid first rotor surface means to a majority of the area of said rotoropening means and to force the binder component through said rotoropening means to form a dispersion, and director means directing themold material component to said dispersion to mix with the bindercomponent.
 28. A foundry machine as set forth in claim 27, wherein saidaxis is substantially vertical.
 29. A foundry machine as set forth inclaim 27, wherein said rotor opening means includes a slot having a longlength relative to the width thereof.
 30. A foundry machine as set forthin claim 27, wherein said means directing the binder component to saidfirst rotor surface means includes, a second rotor surface means havinga substantial vectorial component normal to said axis, and meansdirecting the binder component to said second rotor surface means to bemoved by action of said rotating rotor means to said first rotor surfacemeans.
 31. A foundry machine as set forth in claim 30, wherein saidfirst rotor surface means includes the side of a container and saidsecond rotor surface means includes the bottom of said container.
 32. Afoundry machine as set forth in claim 30, wherein said second rotorsurface means includes a plurality of projections extendingperpendicularly from said axis of rotation.
 33. A foundry machine as setforth in claim 32, wherein said projections project from differentlocations along said axis of rotation.
 34. A foundry machine as setforth in claim 30, wherein said second rotor surface means includes aninner rotor projection surface forming an acute angle with said axis ofrotation.
 35. A foundry machine for mixing a mold material component anda binder component, comprising in combination, rotor means having afirst rotor surface with rotor opening means therein, said rotor openingmeans having a major vectorial component parallel to the axis ofrotation of said rotor means, means directing the binder component tosaid rotor means, director means directing the mold material componentto substantially envelop said rotor means, and means rotating said rotormeans to disperse the binder component through said rotor opening meansto form a dispersion to enable mixing of the components only when themold material component is freely falling by action of gravity.
 36. Afoundry machine as set forth in claim 35, wherein said director meansincludes director means directing the mold material component toconverge after passing said rotor means.